Structured wiring box

ABSTRACT

An expandable structured wiring box ( 100 ) for managing and organizing wiring for household communications systems is disclosed. An adaptive trim ring ( 202 ) is provided for increasing internal space to allow for additional internal components. The trim ring ( 202 ) also hinges wall edges ( 208 A,  208 B) caused during installation of the box ( 100 ).

FIELD OF THE INVENTION

The present invention is generally related to structured boxes used to manage and organize wiring for household communications systems and to improve access thereto and maintenance thereof. More specifically, it is related to such a box that is adapted for mounting within a wall and to means for expanding such a box, as additional space is required therein.

BACKGROUND AND OBJECTS OF THE INVENTION

Household structured wiring boxes are used to centrally unite input signal wires and output wires distributed throughout the house. Since each house may have different signals coming in and differing distribution needs, distribution and amplification modules are placed in the structured wiring box to customize the configuration and distribution for each house.

In current structured wiring boxes, it is very time consuming to wire up the modules, add new modules or wiring, or rewire to change the distribution. This is due in part to the confined space of boxes and the growing obstruction caused by the wires that are connected therein, especially as more wires and electrical components are added during aftermarket upgrading. The ideal structured wing box would be organized in a manner that simplifies later upgrading and reduces confusion, unlike current structured wiring boxes.

In existing boxes, upgrading to add significantly new functionality even within one manufacturer's product line can also present problems, and sometimes requires the complete removal and replacement of an entire original box at great expense and trouble. The ideal structured wiring box would support changing distribution needs and potentially new modules over its lifespan, and would be both flexible and expandable.

Further, since these boxes are built into the home, the ideal structured wiring box would have a housing that anticipates and accepts future technology without requiring carpentry or reconstruction of the home over the life of the home rather than just over the shorter life of the technology. Functional and permanently installed portions of the box would remain functional over the life of the home and would not become obsolete as the technology within becomes obsolete. Visible portions of the box would either remain fashionable over the life of the home and not become outdated as the technology within becomes outdated, or could be easily replaced as styles later change without requiring carpentry or reconstruction of the home.

It is therefore an object of the present invention to provide a structured wiring box for household use that is easier to install and use and that more readily facilitates initial wiring and later upgrading.

It is a further object to provide such a structured wiring box that eliminates the need for reconstruction and carpentry during later upgrading and over the life of the home into which it is installed.

It is a further object to provide such a structured wiring box that is adaptable to remain aesthetically pleasing over the expected life of the home, rather than just over the life of the technology within the box.

Further objects and advantages of the present invention will become apparent upon review of the following drawings and description of a preferred embodiment thereof.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other objects and features of the invention will become more apparent upon a perusal of the following description taken in conjunction with the accompanying drawings wherein:

FIG. 1 is a perspective view of a structured wiring box according to the preferred embodiment of the invention;

FIG. 2 is a cross-sectional view taken along lines 2-2 of FIG. 1;

FIG. 3 is a perspective view of the structured wiring box of FIG. 1 with the cover door, module door, and computer server door opened;

FIG. 4 is an exploded perspective view of the structured wiring box of FIG. 1;

FIG. 5 is a left side view of the structured wiring box of FIG. 1;

FIG. 6 is a front view of the structured wiring box of FIG. 1 with the cover door opened; and

FIG. 7 is a detailed view of the trim ring of the structured wiring box of FIG. 1.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT OF THE INVENTION

A structured wiring box 100 according to the preferred embodiment of the invention is depicted in FIGS. 1 through 7. The structured wiring box 100 consists of a base box housing 101 that fits between standard sixteen-inch-on-center wall studs. As shown in FIG. 3, the base box 101 is formed by right and left side panels 102, 103, a top panel 104, a bottom panel 105, and a back panel 106. Together, the panels 102-106 form a housing chamber 112 having a front opening 110. Both the right and left side panels 102, 103 and the top and bottom panels 104, 105 are parallel and arranged orthogonally with the also parallel back panel 106 and opening 110 such that the housing 100 and housing chamber 112 are cubic. Formed in the top and bottom panels 104, 105 are access ports 108 for entry and exit of wiring extending into and out of the chamber 112. Preferably, the right and left panels 102, 103 are spaced slightly less than sixteen inches apart to facilitate mounting of the box 101 between wall studs (not shown).

In a default minimum configuration, a flat front cover (not shown) is used to close the structured wiring box 100 and hide the rough edges of sheet rock surrounding the mounting hole in the house's wall. All wires, components, and modules are contained within a volume 112 (FIG. 3) defined by the base box 101 and a flat front cover (not shown).

As illustrated in FIGS. 1 and 2, each side panel 102, 103 of the box 101 has a plurality of vertically spaced apart regions 182 which are flexible to allow adjustment of the box 101 within warped studs. Centrally located within each region 182 is a horizontally elongated mounting slot 184 for receiving a suitable fastener (not shown) such as a screw. Each slot 184 is positioned in an outwardly indented bracket portion 183 of the region 182. Formed within each region 182 are a pair of vertically oriented stress relief slots 185, 186 located on opposite sides of each mounting slot 184 and another vertical pair including one slot 187 located above the mounting slot 184 and straddled by and parallel to the stress relief slots 185, 186 and another slot 188 located below the mounting slot 184 and straddled by and parallel to stress relief slots 185, 186. Thus, the relief slots 185-188 partially encompass the stress relief regions 182. During the insertion of screw fasteners (not shown) through the mounting slots 184 and into penetrating engagement with warped adjacent studs (not shown) of a wall, the stress relief regions 182 can deflect outwardly and thereby prevent other deformation of the box 101. Thus, the structured wiring box 101 maintains its form in spite of being tightly anchored to imperfect studs.

For non-minimal configurations, or when retrofitting significant upgrades, a decorative trim ring 202 (FIG. 7) is secured to the outer edge of the box 101.

The trim ring 202 includes a flange portion 203 extending parallel to the wall space so as to hide rough edges of the sheet rock hole providing a pleasing appearance for the unit on the wall. Other functions of the trim ring 202 are provided by built-in hinge pins 208A spaced along a left vertical section 209 of the trim ring 202 and hinge pins 208B spaced along a right vertical section 211 of the trim ring 202. The hinge pins 208A, 208B are mounted on tabs 212 secured to a sheet metal strip 213 projecting inwardly from an inner periphery of the trim ring 202. Holes 215 extending through the tabs 212 and strip 213 receive screws (not shown) that secure the ring 202 to inner surfaces of the side panels 102, 103 of the box 101. The outer periphery of the trim ring 202 (FIG. 2) is formed by an inwardly curved rim 217 having an edge 218 for engaging the wall face (not shown) surrounding the box 101. Hinge pins 208A allow the easy addition of an outwardly projecting swinging cover door 206 as described below while hinges 208B allow the easy addition of swinging electrical component and module retaining doors 203, 205 (FIG. 3). Thus, addition of the trim ring 202 allows for upgrading without replacement of base box 101.

The hinge pins 208A allow a default cover (not shown) to be easily replaced with the outwardly projecting cover door 206. During such replacement, the hinge pins 208A receive hinge sleeves 228 mounted on door 206. Together, the pins 208A and sleeves 228 form hinges 231 which allow swinging movement of the door between a closed position covering a composite chamber including the housing chamber 112 and an extension chamber 222 (described below) and an open position allowing access thereto. Similar, hinge sleeves 218 are provided on the module doors 203, 205. As shown in FIGS. 2, an inner surface 221 of the cover door 206 is outwardly spaced from the trim ring 202 by a distance B so as to establish a portion of an extension chamber 222 having a depth C. The space between the inner door surface 221 and the trim ring 202 is concealed by an inwardly projecting rim 224 along the perimeter of the door 206. In addition, the depth A of the trim ring 102 provided by the rim 217 establishes another portion of the extension chamber 222 which accommodates more and/or larger components. The extension chamber 222 provides space for modules and components that are otherwise too large to fit only within housing chamber 112. For example, the extension chamber accommodates the swinging module doors 203, 205 as well as an outer portion of a removable rack 225 for retaining electrical components. Consequently, a new house built with minimal structured wiring cost can later support very complex configurations and many additional or larger components as upgrades or retrofit options are desired.

The hinges 231 are made with the bottom hinge pin 208A, 208B of a set longer than the others to allow for easier installation of the door 206 and modules 203, 205. The different length hinge pins allow the bottom hinge pin to be aligned with a hinge sleeve 228 and partially slid on without alignment of the other hinges. Once a bottom hinge sleeve 228 has been partially slid on a bottom pin 208, the remaining pins and sleeves are aligned and the door or module is moved into a fully retained position.

It should be understood that the afore-described is merely the preferred one of many possible embodiments of the invention, and that the scope of the invention should therefore only be limited according to the following claims. 

1. A box for containing wiring and electrical components and comprising: a housing having a plurality of closed side panels and a front opening to define an open-faced housing chamber, said housing adapted for installation within a hole in the face of a wall such that said front opening is substantially coplanar with the face of the wall; an openable cover adapted for selectively covering and uncovering said front opening; and a removable annular extension ring surrounding said front opening and substantially completely disposed between said front opening and said openable cover, said ring and said cover shaped and arranged to define an extension chamber communicating with said housing chamber wherein said housing chamber and extension chamber cooperate to provide a storage chamber for containing the wiring and electrical components and said openable cover allows selective access to said storage chamber.
 2. A box as in claim 1 wherein said extension ring comprises a flange extending outwardly from said side panels along the plane of the face of the wall, and is thereby adapted to cover the hole in the face of the wall.
 3. A box as in claim 1 wherein said housing has a back panel and wherein said front opening and back panel are parallel, and said plurality of side panels is four and comprises parallel right and left panels and parallel top and bottom panels arranged orthogonally with said parallel front opening and back panel such that said housing and said housing chamber are cubic.
 4. A box as in claim 3 wherein at least one of said top and bottom panels comprises at least one access port for allowing the entrance and exit of wiring to and from said housing chamber.
 5. A box as in claim 4 wherein said parallel left and right panels are slightly less than sixteen inches apart.
 6. A box as in claim 5 wherein said extension ring comprises a flange extending outwardly from said side panels along the plane of the face of the wall, and is thereby adapted to cover the hole in the face of the wall.
 7. A box as in claim 1 wherein said openable cover is connected to said ring by and openable about at least one hinge.
 8. A box as in claim 7 wherein said extension ring comprises a flange extending outwardly from said side panels along the plane of the face of the wall, and is thereby adapted to cover the hole in the face of the wall.
 9. A box as in claim 7 wherein said housing has a back panel and wherein said front opening and back panel are parallel, and said plurality of side panels is four and comprises parallel right and left panels and parallel top and bottom panels arranged orthogonally with said parallel front opening and back panel such that said housing and said housing chamber are cubic.
 10. A box as in claim 9 wherein at least one of said top and bottom panels comprises at least one access port for allowing the entrance and exit of wiring to and from said housing chamber.
 11. A box as in claim 10 wherein said parallel left and right panels are slightly less than sixteen inches apart.
 12. A box as in claim 11 wherein said extension ring comprises a flange extending outwardly from said side panels along the plane of the face of the wall, and is thereby adapted to cover the hole in the face of the wall.
 13. A box as in claim 7 wherein each of said at least one hinge comprises a cover portion affixed to said cover and a ring portion affixed to said ring and adapted to mate pivotally with said cover portion to allow said covering and uncovering of said open front panel.
 14. A box as in claim 8 wherein said cover portion and said ring portion are separable and thereby adapted to allow separation of said cover from said ring.
 15. A box as in claim 14 wherein said extension ring comprises a flange extending outwardly from said side panels along the plane of the face of the wall, and is thereby adapted to cover the hole in the face of the wall.
 16. A box as in claim 15 wherein said housing has a back panel and wherein said front opening and back panel are parallel, and said plurality of side panels is four and comprises parallel right and left panels and parallel top and bottom panels arranged orthogonally with said parallel front opening and back panel such that said housing and said housing chamber are cubic.
 17. A box for containing electrical components and wiring and comprising: a housing adapted for mounting within a hole extending inwardly from an opening in a planar outer surface of a wall, said housing defining a storage chamber accessible through said opening and comprising side walls for extending into the hole and having outer edges adjacent to a perimeter of the opening; a removable ring extending outwardly from said outer edges and arranged to cover the perimeter of the opening, said ring disposed substantially completely externally of said storage chamber; and a cover pivotally mounted on said ring and movable between a closed position covering said storage chamber and an open position providing access thereof; said cover in said closed position having an inner surface substantially parallel to said planar outer surface and spaced outwardly therefrom so as to define therebetween an extension chamber superimposed over said storage chamber.
 18. A box as in claim 17 wherein said cover is pivotally connected to said ring by at least one hinge.
 19. A box as in claim 18 wherein each of said at least one hinge comprises a cover portion affixed to said cover and a ring portion affixed to said ring and adapted to mate pivotally with said cover portion to allow said cover to move between said open and closed positions.
 20. A box as in claim 17 wherein said ring comprises wall portions extending substantially normal to the wall surface so as to define at least a portion of said extension chamber.
 21. A box as in claim 20 wherein said cover is pivotally connected to said ring by at least one hinge.
 22. A box as in claim 21 wherein each of said at least one hinge comprises a cover portion affixed to said cover and a ring portion affixed to said ring and adapted to mate pivotally with said cover portion to allow said cover to move between said open and closed positions.
 23. A box as in claim 17 wherein an inner surface of said cover is spaced outwardly from said ring so as to define therebetween at least a portion of said extension chamber.
 24. A box as in claim 23 wherein said cover is pivotally connected to said ring by at least one hinge.
 25. A box as in claim 24 wherein each of said at least one hinge comprises a cover portion affixed to said cover and a ring portion affixed to said ring and adapted to mate pivotally with said cover portion to allow said cover to move between said open and closed positions.
 26. A box as in claim 23 wherein said ring comprises wall portions extending substantially normal to the wall surface so as to define at least a portion of said extension chamber.
 27. A box as in claim 26 wherein said cover is pivotally connected to said ring by at least one hinge.
 28. A box as in claim 27 wherein each of said at least one hinge comprises a cover portion affixed to said cover and a ring portion affixed to said ring and adapted to mate pivotally with said cover portion to allow said cover to move between said open and closed positions.
 29. A box as in claim 17 wherein said cover is pivotally connected to said ring by a plurality of hinges each comprising a hinge sleeve and a hinge pin received by said hinge sleeve, and wherein the length of at least one of said hinge pins is greater than at least one other said hinge pin. 